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Tetra Pak Frigus SF 300-C1 Technical Manual

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TeM
Technical Manual
Frigus SF 300-C1
Z1321173-01en
WARNING
Read and follow all safety precautions before working on or near
this equipment.
Read all safety precautions throughout this manual and on safety
signs attached to this equipment. Failure to follow all safety
precautions could result in death or serious injury.
Doc. No. TeM-Z1321173-01en

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Summary of Contents for Tetra Pak Frigus SF 300-C1

  • Page 1 Technical Manual Frigus SF 300-C1 Z1321173-01en WARNING Read and follow all safety precautions before working on or near this equipment. Read all safety precautions throughout this manual and on safety signs attached to this equipment. Failure to follow all safety precautions could result in death or serious injury.
  • Page 2 100125 Shanghai P.R.China Additional copies can be ordered from Tetra Pak Parts or the nearest Tetra Pak office. When ordering additional copies, always provide the document number. This can be found in the machine specification document. It is also printed on the front cover and in the footer on each page of the manual.
  • Page 3 Doc. No. TeM-Z1321173-01en Issue 2007-02 Shanghai Tetra Pak Hoyer Ice Cream...
  • Page 4 Valid for:...
  • Page 5 Update Log for Doc. No. TeM-Z1321173-01en This table shows all changes made to this manual, such as kits installed and pages added or removed. Date Installed Kit Added Pages Removed Pages Signature (Doc. No.)
  • Page 6 Date Installed Kit Added Pages Removed Pages Signature (Doc. No.)
  • Page 7 i Introduction 1 - 1 (16)
  • Page 8 Introduction General informations about Introduction section This chapter contains basic information about this manual and related Tetra Pak equipment. 1 - 2 (16)

  • Page 9: Table Of Contents

    Table of Contents i Introduction i.1 About the introduction chapter ... . . 1 - 6 Abbreviations and Terminology ... . 1 - 7 Manual information .
  • Page 10 i Introduction This page intentionally left blank 1 - 4 (16)
  • Page 11 i Introduction 1 - 5 (16)

  • Page 12: About The Introduction Chapter

    i.1 About the introduction chapter i Introduction i.1 About the introduction chapter Risk of serious personal injury. To ensure maximum safety, always read the chapter “Safety precautions” before operating or servicing the machine or equipment. This chapter contains basic information about this manual and related Tetra Pak equipment.

  • Page 13: Abbreviations And Terminology

    i Introduction i.2 Abbreviations and Terminology i.2 Abbreviations and Terminology Abbreviation/ Meaning Translation Terminology Cleaning In Place Spare parts catalogue 1 - 7 (16)

  • Page 14: Manual Information

    It is important to keep the manual for the life of the machine or equipment and pass the manual on to any subsequent holder or user. Tetra Pak will not be held responsible for any damage to the machine or equipment caused by not following the instructions given in this manual.

  • Page 15: Page Layout

    i Introduction i.3 Manual information i.3.2 Page Layout Every main page in a manual contains a header and a footer. The page header contains the section name (2) and the chapter name (1). The page footer contains the manual’s document number (3), and the page number(4).

  • Page 16: Page Numering

    i.3 Manual information i Introduction i.3.3 Page Numering A page number has three parts: • chapter number (1) • consecutive page number (2) within the chapter • total number of pages (3) in the chapter. 1 Chapter number 2 Consecutive page number 3 Total number of pages i.3.4 Typographical Conventions...

  • Page 17: Machine Introduction

    Machine Introduction i.4 Machine Introduction i.4.1 Intended use of the machine or equipment The intended use of this Tetra Pak machine or equipment is to inject fruit pieces, nuts, candies and other free flowing granulates into ice cream or similar products.

  • Page 18: Identification

    The below illustration shows an example of the machine plate and its location on the machine or equipment. The machine plate carries data needed when contacting Tetra Pak concerning this specific machine or equipment. 1 Machine type 2 Machine serial number...

  • Page 19: Orientation

    i Introduction i.6 Orientation i.6 Orientation The illustration below shows the orientation of the equipment. This orientation information will be used throughout this manual. A Front B Right-hand side C Left-hand side D Back 1 - 13 (16)

  • Page 20: Hygiene

    i.7 Hygiene i Introduction i.7 Hygiene Ice cream production, like other foodstuffs, requires high sanitary standards. That is why the strictest demands should be made on cleaning of devices and tools getting in touch with the ice cream, ingredients coating and packaging materials.

  • Page 21: How To Use This Operation Manual

    i Introduction i.8 How to Use This Operation Manual i.8 How to Use This Operation Manual Purpose of the operation manual The operation manual provides operators with information on handling and operating the equipment before, during, and after production. Operator workflow Beginning with Chapter 1, the content is structured to follow the operator workflow, as described below.
  • Page 22 i.8 How to Use This Operation Manual i Introduction This page intentionally left blank 1 - 16 (16)
  • Page 23 ii Safety Precautions 1 - 1 (20)
  • Page 24 ii Safety Precautions 1 - 2 (20)
  • Page 25 Table of Contents ii Safety Precautions ii.1Read the safety precautions 2 - 9 ii.1 Read the safety precautions....1 - 5 ii.2 Safety Messages Description....1 - 6 ii.3 Personnel requirements .
  • Page 26 ii Safety Precautions This page intentionally left blank 1 - 4 (20)

  • Page 27: Ii.1 Read The Safety Precautions

    ii Safety Precautions ii.1 Read the safety precautions ii.1 Read the safety precautions All persons operating, servicing, adjusting or otherwise working with or near this machine or equipment must carefully read and follow all safety instructions in this manual and warning signs on the machine or equipment itself.

  • Page 28: Ii.2 Safety Messages Description

    ii.2 Safety Messages Description ii Safety Precautions ii.2 Safety Messages Description A safety message is always accompanied by a safety alert symbol and a signal word. This is the “safety alert” symbol. It is used to alert about poten- tial personal injury hazards. Obey all safety messages that follow this symbol to avoid death or injury.

  • Page 29: Ii.3 Personnel Requirements

    ii Safety Precautions ii.3 Personnel requirements ii.3 Personnel requirements Note! Personnel includes all persons performing work on or near the machine or equipment. Only skilled or instructed persons are allowed to work with the machine or equipment. ii.3.1 Skilled person A skilled person must have relevant education and experience to enable him or her to identify hazards, analyze risks, and avoid hazards which electricity, mechanics, chemicals, and supply systems can create.

  • Page 30: Ii.4 Safety Signs

    ii.4 Safety signs ii Safety Precautions ii.4 Safety signs ii.4.1 Safety Signs WARNING Hazards without safety signs drastically increase the risk of death or serious injury. Replace all missing or damaged safety signs immediately. There are two types of safety sign •...

  • Page 31: Ii.4.2 Location Of Safety Signs

    ii Safety Precautions ii.4 Safety signs ii.4.2 Location of safety signs Note! Always ensure that all safety signs on the machine or equipment are undamaged and in their correct position after installation and maintenance. The illustration below indicates where the safety signs are located. 1 - 9 (20)

  • Page 32: Ii.5 Protective Devices

    ii.5 Protective devices ii Safety Precautions ii.5 Protective devices DANGER Unshielded hazards. Never inch or run the machine or equipment if any component of the safety system is inoperative. All inoperative components of the safety system must be changed immediately. Note! Activating a safety device, such as an EMERGENCY STOP, or opening an interlocked safeguard does not switch off the power supply to the machine or equipment.

  • Page 33: Ii.6 Personal Protection

    ii Safety Precautions ii.6 Personal protection ii.6 Personal protection Note! Personal protection required when handling hazardous materials is specified for each substance, see the section “Hazardous materials”. ii.6.1 Hearing Protection WARNING Hazardous noise level. Risk of impaired hearing. Wear hearing protection.

  • Page 34: Ii.7 Hazardous Materials

    ii.7 Hazardous materials ii Safety Precautions ii.7 Hazardous materials WARNING Contact with chemicals can cause injury and illnesses. Always follow the manufacturer’s instructions when handling chemical products. Always make sure that • the showers work • an eyewash device, movable or wall-mounted, is available and operational •...

  • Page 35: Ii.7.1 Products For Cleaning And Sterilization

    ii Safety Precautions ii.7 Hazardous materials ii.7.1 Products for cleaning and sterilization The cleaning of the machine and its components previews to use of chemical products. The following table indicates the various type of recommended products. Detergent Descaler Disinfectant SU928 (Diversey Lever) P3-topax 99 (60°„C) (Henkel Ecolab) P3-topax 99 (60°„C) (Henkel Ecolab) SU616 (Diversey Lever)

  • Page 36: Ii.7.2 Personal Protective Equipment

    ii.7 Hazardous materials ii Safety Precautions ii.7.2 Personal Protective Equipment The personal protective equipment for products for cleaning and sterilization • safety goggles. • protective gloves made of neoprene. • apron • shoes made of PVC, PE plastic, or rubber. 1 - 14 (20)

  • Page 37: Handling

    ii Safety Precautions ii.7 Hazardous materials Handling WARNING Sudden and violent chemical reaction.Avoid any contamination of products for cleaning and sterilization. The products for cleaning and sterilization they can react suddenly and violently with many compounds or if it is contaminated. Ensure that equipment used for handling and diluting the products is clean before it comes in contact with the products.
  • Page 38 ii.7 Hazardous materials ii Safety Precautions Storage The products for cleaning and sterilization must be stored in the original container delivered by the supplier. Keep the container upright and fitted with its proper cap. Make sure that the area used for storage of products for cleaning and sterilization is: •...

  • Page 39: Ii.8 Supply Systems

    ii Safety Precautions ii.8 Supply systems ii.8 Supply systems ii.8.1 Electrical cabinet DANGER Hazardous voltage. Electric shock will cause death or serious injury. The power supply disconnecting device must be turned OFF and secured with a lock before any service is carried out inside the electrical cabinet Note! The key to the lock must be removed by the service technician or the electrician, and retained in his/her possession until all work is...

  • Page 40: Ii.8.2 Power Supply

    ii.8 Supply systems ii Safety Precautions ii.8.2 Power supply DANGER Hazardous voltage and moving machinery. The power supply disconnecting device must be turned OFF and secured with a lock before any service is carried out. Note! The key to the lock must be removed by the service technician or the electrician, and retained in his/her possession until all work is completed.

  • Page 41: Ii.8.3 Air Supply

    ii Safety Precautions ii.8 Supply systems ii.8.3 Air Supply WARNING Compressed air. Close the main air valve before any maintenance. Certain maintenance procedures may require the air supply systems to be on. These exceptions are clearly stated in the Maintenance Manual. 1 - 19 (20)
  • Page 42 ii.8 Supply systems ii Safety Precautions This page intentionally left blank 1 - 20 (20)
  • Page 43 1 Installation 1 - 1 (12)
  • Page 44 1 Installation 1 - 2 (12)
  • Page 45 Table of Contents 1 Installation 1.1 General Description ....1 - 5 1.2 Technical Data ......1 - 6 1.3 Reception .
  • Page 46 1 Installation This page intentionally left blank 1 - 4 (12)

  • Page 47: General Description

    1 Installation 1.1 General Description 1.1 General Description Frigus 300 is a simple and robust continuous ice cream freezer, designed and built according to the latest guidelines for hygienic food processing machinery. All food-interfacing surfaces are made in stainless materials (stainless steel, hard chromium-plated stainless steel, hard chromium-plated nickel, and EPDM rubber).

  • Page 48: Technical Data

    1.2 Technical Data 1 Installation 1.2 Technical Data Shipping data: Net weight 750 kg Gross weight 900 kg Volume 2.9 m Weight, ready for operation 750 kg Maximum weight per leg 250 kg Mains connection, 50 Hz, 3 Phases 415V Power consumption 10 kW Refrigerant, weight (R404A)
  • Page 49 1 Installation 1.2 Technical Data Water consumption / flow rate: 1 - 7 (12)

  • Page 50: Reception

    The cases may be easily transported by a lift truck. If the crate has been damaged during transport, notify the insurance company, and also the shipping agent and Tetra Pak Hoyer immediately and do not proceed with removal of packaging until authorised by the insurance company.

  • Page 51: Installation Instructions

    1 Installation 1.4 Installation Instructions 1.4 Installation Instructions The machine is fully tested and regulated in the factory with about one hour of ice cream production prior to shipment to the customer. Installation simply involves connecting up the pipes for the condenser cooling water supply, ice cream mix intake and outlet, compressed air supply and electric power supply.

  • Page 52: Connection To Cooling Water

    1.5 Connection to cooling water 1 Installation 1.5 Connection to cooling water Connect the factory’s water supply to the condenser’s inlet pipe, “E” in “Refrigerating system” Refrigerating system The condenser inlet pipe features a pressure-controlled valve that reduces the consumption of water. Connect the water drain pipe, “F”.

  • Page 53: Connection, Mix Inlet/Outlet

    WARNING Make sure that the machine and its installations are in accordance with local regulations and safety demands before it is taken into service. Immediately notify Tetra Pak Hoyer of any fault or irregularity. 1 - 11 (12)

  • Page 54: Connection To Electrical Installations

    1.7 Connection to electrical installations 1 Installation 1.7 Connection to electrical installations The freezer has been factory tested for the voltage and frequency specified in the type plate which is located on the high-voltage cabinet. An authorized electrician must connect the freezer to the mains. This part of the installation process always takes place at the customer’s own risk unless otherwise agreed in the contract.
  • Page 55 2 Maintenance 2 - 1...
  • Page 56 2 Maintenance 2 - 2...
  • Page 57 Table of Contents 2 Maintenance 2.1 Preventive maintenance ....1 - 5 2.1.1 Operation period ..... . 1 - 5 2.1.2 Outside the operation period .
  • Page 58 2 Maintenance This page intentionally left blank 2 - 4...
  • Page 59 2 Maintenance 2.1 Preventive maintenance 2.1 Preventive maintenance This freezer has been designed so that it needs a minimum of maintenance. Wherever possible, lifetime lubricated bearings have been used in order to minimize day-to-day maintenance. 2.1.1 Operation period Daily: • Cleaning according to the instructions under “Daily cleaning”.
  • Page 60 2.2 Mechanical Overhaul 2 Maintenance 2.2 Mechanical Overhaul • Inspect the dasher drive shaft. If the drive shaft is noisy during operation, dismantle it and change bearings and O-rings. • Inspect the rotating shaft seal. The two gliding surfaces must always be mirror finished;...
  • Page 61 3 Spare Parts Catalogue 3 - 1 (36)
  • Page 62 3 Spare Parts Catalogue Information about spare parts ....1 - 3 3.0.1 General ....... . . 1 - 3 3.0.2 How to order spare parts .

  • Page 63: Information About Spare Parts

    The type and serial number is always found on the machine identification plate. If you want to know more about Hoyer spare parts from Tetra Pak - or about any other service products - contact your nearest Tetra Pak Service representative.

  • Page 64: Pump 1-2

    3.1 Pump 1-2 3 Spare Parts Catalogue 3.1 Pump 1-2 3.1.1 Bom No. 50101102 ESCRIPTION 30304005 gear & motor 10602062 bolt M8 x 40 10601014 nut M8 10603021 washer 8 10604003 spring washer 8 30201051 collar 10602047 bolt M6 x 12 10603023 washer 6 10604002...
  • Page 65 3 Spare Parts Catalogue 3.1 Pump 1-2 ESCRIPTION 30909001 M6 grease nipple 30201056 pump pin 30201106 back ring 10602030 bolt M4 x 12 10604001 spring washer 4 30101018 pump guard part I 10602057 bolt M8 x 20 30903027 pump gasket 30201050 pump housing with clamp 30201058...
  • Page 66 3.1 Pump 1-2 3 Spare Parts Catalogue 3 - 6 (36)
  • Page 67 3 Spare Parts Catalogue 3.1 Pump 1-2 ESCRIPTION 10603021 washer 3 - 7 (36)
  • Page 68 3.1 Pump 1-2 3 Spare Parts Catalogue 3 - 8 (36)
  • Page 69 3 Spare Parts Catalogue 3.1 Pump 1-2 3 - 9 (36)

  • Page 70: Cylinder Assembly

    3.2 Cylinder Assembly 3 Spare Parts Catalogue 3.2 Cylinder Assembly 3.2.1 Bom No. 50101104 ESCRIPTION 30201078 thread key 30201085 gasket 30201036 knurled nut 30201137 top cover 10601002 M10 nut 10602424 M10x55 bolt 10601001 M10 nut 30302001 cylinder 30201062 dasher 30201127 whipper 59609120421 bush ß¹16/ß¹25...
  • Page 71 3 Spare Parts Catalogue 3.2 Cylinder Assembly ESCRIPTION 59609120423 blade 30201031 mounting tool 3 - 11 (36)
  • Page 72 3.2 Cylinder Assembly 3 Spare Parts Catalogue 3 - 12 (36)
  • Page 73 3 Spare Parts Catalogue 3.2 Cylinder Assembly 3 - 13 (36)

  • Page 74: Pressure Regulating Valve

    3.3 Pressure regulating valve 3 Spare Parts Catalogue 3.3 Pressure regulating valve 3.3.1 Bom No. 50101105 ESCRIPTION 30903069 1'' seal ring 31003004 clamp ring 30201018 housing 30201019 piston 30903007 o-ring 22.5x3 30201016 cover 30201020 guide 30909007 spring 30201037 knurled nut 30201017 hand grip 50101044...

  • Page 75: Mix Tank

    3 Spare Parts Catalogue 3.4 Mix Tank 3.4 Mix Tank 3.4.1 Bom No. 50101106 ESCRIPTION 30309001 mix tank box 30309001 mix tank cover 59609180621 float 30909011 lock pin 30201094 valve seat 31003004 clamp liner-welding 30903070 1 1/2'' seal ring 30201079 inlet pipe 30903057 o-ring 9.12x3.53...
  • Page 76 3.4 Mix Tank 3 Spare Parts Catalogue 3 - 16 (36)
  • Page 77 3 Spare Parts Catalogue 3.4 Mix Tank 3 - 17 (36)

  • Page 78: Main Motor Assembly

    3.5 Main Motor Assembly 3 Spare Parts Catalogue 3.5 Main Motor Assembly 3.5.1 Bom No.50101110 ESCRIPTION 30201063 Main motor console 30201003 Shaft for rotor 30201001 Claw around the main shaft 30201033 Machine the Scew 30201047 Machine the pin 10608003 Spilt pin 30201064 Plate for main motor 30303001...
  • Page 79 3 Spare Parts Catalogue 3.5 Main Motor Assembly ESCRIPTION 10607001 Feather Key 10*8*40 30906001 Pulley for V-Belt 315 10602058 Bolt M8*20 30201038 Distance ring 30901001 Bearing 30201070 Cover plate 30903023 O-Ring 30101021 Drip tray cylinder 30902038 O-Ring 30201046 Machine the pin 10608027 Spilt pin 30201035...
  • Page 80 3.5 Main Motor Assembly 3 Spare Parts Catalogue 3 - 20 (36)

  • Page 81: Cooling System

    3 Spare Parts Catalogue 3.6 Cooling System 3.6 Cooling System 3.6.1 Bom No. 50101113 ESCRIPTION 10602018 bolt M12*55 10603005 washer 10604005 Spring washer 12 10601003 nut M12 10404002 asbestos washer 10609002 1/4 forged nut 10303004 16 copper pipe 1/4 10303002 2 copper pipe 1/2 30302002 condenser...
  • Page 82 3.6 Cooling System 3 Spare Parts Catalogue 3 - 22 (36)
  • Page 83 3 Spare Parts Catalogue 3.6 Cooling System ESCRIPTION 10303005 1 copper pipe 7/8 30308028 R22 discus compressor 30501013 vibration absorber 30201012 connection 1 10609003 5/8 flared nut 10303002 3 copper pipe 1/2 10303002 13 copper pipe 1/2 10303004 11 copper pipe 1/4 10602039 bolt M4*8 10601010...
  • Page 84 3.6 Cooling System 3 Spare Parts Catalogue 3 - 24 (36)
  • Page 85 3 Spare Parts Catalogue 3.6 Cooling System ESCRIPTION 10609009 90 elbow out/outside 30503001 regulating valve 30201089 bolt M4*12 30201087 handle for hot gas valve 10601012 special nut 30602021 pressure gauge 10601008 nut M22^1.5/10 10303002 10 copper pipe 1/2 10303002 9 copper pipe 1/2 10303003 8 copper pipe 1/2 31101004...
  • Page 86 3.6 Cooling System 3 Spare Parts Catalogue 3 - 26 (36)
  • Page 87 3 Spare Parts Catalogue 3.6 Cooling System ESCRIPTION 30501010 pressure controller 10609006 1/4 connector 30101024 support for meter 10602039 bolt M4*8 10405001 insulation board 13mm 10405002 insulation tube/1 1/8*3/8 10408003 insulation tube/5/8*3/8 3 - 27 (36)
  • Page 88 3.6 Cooling System 3 Spare Parts Catalogue 3 - 28 (36)
  • Page 89 3 Spare Parts Catalogue 3.6 Cooling System 3 - 29 (36)

  • Page 90: Control Panel

    3.7 Control Panel 3 Spare Parts Catalogue 3.7 Control Panel ESCRIPTION 30601001 Current Meter 30402051 Indicator Light,White 30402043 Lampholder 30402002 Lamp 30402050 Mushroom Operating Head Red 30402005 Circular Legend Plate,Yellow 30401230 Contact Block 2NC 30402049 Booted Pushbutton Blue 30402047 Contact Block 1NO 30402044 Selector Head O - I 30402047...
  • Page 91 3 Spare Parts Catalogue 3.7 Control Panel 3 - 31 (36)

  • Page 92: Power Cabinet

    3.8 Power cabinet 3 Spare Parts Catalogue 3.8 Power cabinet ESCRIPTION 30405004 Transformer 380V-->220V 8T10 30405003 Transformer 380V-->24V 30401208 Single Pole Circuit breaker 30403033 Safety Relay 30403001 Terminal Block 30403002 Current Limiter 10803003 3-Pole 63A busbar 30403175 Circuit breaker 10Q2 30403165 Circuit breaker 30403166...
  • Page 93 3 Spare Parts Catalogue 3.8 Power cabinet ESCRIPTION 30401001 Terminal Cover 30401007 MCB Handle Accessories 3 - 33 (36)
  • Page 94 3.8 Power cabinet 3 Spare Parts Catalogue 3 - 34 (36)
  • Page 95 3 Spare Parts Catalogue 3.8 Power cabinet 3 - 35 (36)
  • Page 96 3.8 Power cabinet 3 Spare Parts Catalogue This page intentionally left blank 3 - 36 (36)
  • Page 97 4 Electrical Documents 4 - 1 (14)
  • Page 98 4 Electrical Documents 4 - 2 (14)
  • Page 99 Table of Contents 4 Electrical Documents 4.1 Index ....... . 1 - 5 4.2 Power Cabinet Layout.
  • Page 100 4 Electrical Documents This page intentionally left blank 4 - 4 (14)

  • Page 101: Index

    4 Electrical Documents 4.1 Index 4.1 Index 4 - 5 (14)

  • Page 102: Power Cabinet Layout

    4.2 Power Cabinet Layout 4 Electrical Documents 4.2 Power Cabinet Layout 4 - 6 (14)

  • Page 103: Control Panel Layout

    4 Electrical Documents 4.3 Control Panel Layout 4.3 Control Panel Layout 4 - 7 (14)

  • Page 104: Control Panel Wiring Sider

    4.4 Control Panel Wiring Sider 4 Electrical Documents 4.4 Control Panel Wiring Sider 4 - 8 (14)

  • Page 105: Pump Motor

    4 Electrical Documents 4.5 Pump Motor 4.5 Pump Motor 4 - 9 (14)

  • Page 106: Main Motor

    4.6 Main Motor 4 Electrical Documents 4.6 Main Motor 4 - 10 (14)

  • Page 107: Refrigerant Comp

    4 Electrical Documents 4.7 Refrigerant Comp. 4.7 Refrigerant Comp. 4 - 11 (14)

  • Page 108: Transformers

    4.8 Transformers 4 Electrical Documents 4.8 Transformers 4 - 12 (14)

  • Page 109: Emergency Circuit

    4 Electrical Documents 4.9 Emergency Circuit 4.9 Emergency Circuit 4 - 13 (14)

  • Page 110: Circuit Diagram

    4.10 Circuit Diagram 4 Electrical Documents 4.10 Circuit Diagram 4 - 14 (14)
  • Page 112 This page intentionally left blank...

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